Research Project | itsOWL-ScAut - BECKHOFF New … · · 2017-07-19intelligent feedback control system with PC-based control ... Programming in IEC 61131-3 and the C or C++ languages

Research Project | itsOWL-ScAut

Scientific Automation – Integration of Engineering Findings in Standard Automation

© it´s OWL Clustermanagement GmbH | www.its-owl.com 2

Flagship high-tech strategy of Federal Government

Regional pooling of economy and science along the value chain

15 leading-edge cluster represent high-tech competence ensuring

growth and employment

Leading-Edge Cluster it´s OWL

Funding: 40 Mio. € over 5 years for each Cluster

Funding by BMBF ends this year

Continuity of the Leading-Edge Cluster assured through

sponsoring from the federal state NRW

Beckhoff runs two projects:

Scientific Automation (itsOWL-ScAut)

Extreme Fast Automation (itsOWL-efa)

it´s OWL – Intelligent technical systems

Leading-Edge Cluster

sponsored by supported by

© it´s OWL Clustermanagement GmbH | www.its-owl.com


Project overview

Scientific Automation approaches

Consistent engineering

Smart Factory (ScAut-Demonstrator)

Summary

3


Manufacturers are facing the challenge

1. To produce customized products with existing production technologies

2. To realize a efficient and sustainable production, with the objective to stay competitive

Requirements for production systems

Highly flexible, precise, fast in lot size 1

Reduction of breakdowns, downtimes, quality issues of the production and of the product

Approaches to fit the requirements

Intelligence realized by control technology (Scientific Automation)

Control technology with high performance

it´s OWL – Intelligent technical systems

Initial situation: Challenges, requirements


Objective: Integration of Engineering Findings in Standard Automation

Results: Scientific Automation Plattform

Architecture for intelligent networked production systems


– Measurement technology, condition monitoring, power monitoring,

intelligent feedback control system with PC-based control

– Control- and cloud-based analytics

Consistent, model based engineering

Period: 1 July 2012 to 30 June 2017

Project volume: 5.6 Million Euros

Research Project | itsOWL-ScAut – Scientific Automation

Objective, Results

sponsored by

Projektpartner

supported by

5



Project Partners

Beckhoff Automation GmbH

Heinz Nixdorf Institut, University of PaderbornScience

Automation

technology

Hüttenhölscher

Maschinenbau

GmbH & Co. KG

Schirmer

Maschinen

GmbH

IMA Klessmann

GmbH wood-

working systems

Machine

construction

Nobilia-Werke J. Stickling GmbH & Co. KGConsumer

goods

production

Cross-

section

projects

Sustain-

ability

measures

Spitzen-

cluster

it´s OWL

Beckhoff Automation GmbH & Co. KG

6



PC-Control + Scientific Automation

Scientific

Automation

Standard

automation

technology

Engineering

sciences

IT-Technology

PC-Technology

Measurement

technology



Development of control technology

Complexity

1970 1975 1980 19901985 1995 20052000 2010 2015 2020

Integration of

visualization

PLC

motion (PTP, NC, robotics)

control technology

communication

special functions

Standard Automation

PC Control

Motion

PLC

operation, visualization,

data storage

Industrial PC

8



Development of control technology

Complexity

1970 1975 1980 19901985 1995 20052000 2010 2015 2020

Scientific Automation

PC-Control

Integration of

Measurement technology

Condition Monitoring

Power Management

…

Measurement technology +

engineering science

Integration of

visualization

PLC

motion (PTP, NC, robotics)

control technology

communication

special functions

Standard Automation

PC Control

Motion

PLC

operation, visualization,

data storage

Industrial PC

9



Project overview




Summary

10


Variety of application results

Online and offline condition monitoring,

Predictive maintenance,

Pattern recognition,

Machine optimization,

Long term storage of data.

The applications include Scientific Automation solutions elements, e.g.:

Bus terminals and software for consistent, cycle-synchronous

data acquisition

Software for data analysis and evaluation


Scientific Automation leads to Smart Factories


Measurement technology: Force measurement, vibration measurement,

temperature measurement, …

Analysis: TwinCAT Scope, Gantt-Chart

Power management: Energy monitoring, data evaluation

Condition monitoring: Power spectrum, bearing monitoring, tool breakage

monitoring, balancing of rotary equipment

Data acquisition and analysis with TwinCAT Analytics


Variety of realized Scientific Automation solution elements


ScAut demonstration: Ball bearing monitoring at the drilling spindle,

balancing of rotary equipment, analysis of use cases for order analysis

Schirmer: Tool breakage control (drill breakage)

Hüttenhölscher: Ball bearing monitoring at drilling spindle,

tool breakage control

IMA: Vibration analysis Kontur-Fräsaggregat


Sample application – Condition Monitoring


ScAut demonstration: Energy consumption of single modules, single

systems and overall cloud-based analysis

Hüttenhölscher: Energy consumption of single modules and of the whole

system portable measurement system, measurements at nobilia

Schirmer: Long term measurement of energy consumption at customer

machinery energy costs per produced part, strategies for energy

optimization

IMA: Energy measurement Kontur-Fräsaggregat


Sample application – Power Monitoring


ScAut demonstration: Energy consumption of single modules, single

systems and overall cloud-based analysis

Hüttenhölscher: Energy consumption of single modules and of the whole

system portable measurement system, measurements at nobilia

Schirmer: Long term measurement of energy consumption at customer

machinery energy costs per produced part, strategies for energy

optimization

IMA: Energy measurement Kontur-Fräsaggregat



1200 mm

1400 m

m

Standard window




Sawing process

Eff

ec

tive

po

we

r P

(W

)

Air

flo

w (

l/m

in)

Time (s)

Stab 8 – 07.03.2014 – 4 parts

Power +S3 Air flow VU-Saw

Sawing causes high

energy consumption

1200 mm

1400 m

m

Standard window

© it´s OWL Clustermanagement GmbH | 21 April, 2017 17

Procedure:

Long term measurement of energy consumption

Identification of energy intensive process steps

Development of strategies for a reduction in energy consumption

Strategies:

Shut off nonproductive components

Use different operational modes

Result:

Use different modes during operation

17 % reduction in energy consumption





18

Project overview




Summary

© it´s OWL Clustermanagement GmbH | 21 April, 2017 19

Automation platform TwinCAT 3

Programming in IEC 61131-3 and the C or C++ languages

Object orientation, modularization

Integration of MATLAB®/Simulink®

TC Condition Monitoring library

Data evaluation and visualization with TwinCAT 3 Scope

TwinCAT XCAD – data exchange between engineering tools

Engineering in the Cloud


Scientific Automation enables consistent engineering

© it´s OWL Clustermanagement GmbH | 21 April, 2017


Scientific Automation enables consistent engineering

REQUIRMENTS-

ENGINEERING

SIMULATION/

VIRTUAL COMMISSIONING

ENGINEERING REAL WORLD

PRELIMINARY DESIGN IMPLEMENTATIONDETAILED DESIGN

common data format

BigData

TwinCAT

configuration

electrical

Engineering

E-CAD

Modeling of the

control

UML

feasibility/

initial models

CAD

MATLAB

UML

UML TwinCAT

Scope

simulation/

commissioning

TwinCAT

EtherCAT Simulation

Gantt-Chart / Realtime Monitor

configuration

diagnosis (Scope, Gantt)

control-software

mechanical

Engineering

CAD, MATLAB

MODELICA

Implementation of the

control

(PLC/HMI/MES/ERP)

TC3 XCAD Interface

order/

requirements

ScAut – solution

elements

20



Project overview




Summary


Objective: Monitored production of customized

products in lot size 1

Product: Parts with different milling contours

General requirements:

Individual choice of milling contour

Individual number of parts per order

Quality assurance by weight measurement

Energy efficient production

Reliable production process


ScAut-Demonstrator | Monitored, flexible production


Objective: Monitored production of customized

products in lot size 1

Product: Parts with different milling contours

Production process:

Placing a order

Removal of the necessary part (1)

Identification of the part via a

RFID-Reader (2)

Machining (3)

Quality assurance by weighting (4)

Storage of the finished product (5)



Station 1

Removal

Station 2

Identification

Station 3

Machining

Station 4

Quality

assurance

Station 5

Storage


Realization of different control and monitoring

functions on one single control – Many-Core-Control

with the automation software TwinCAT

Flexible transport: linear transport system XTS

– Servo control, Motion Control

– Collision avoidance, centrifugal force limitation

– Condition Monitoring

Handling: TC Robotic

– Control of a Delta-Robot

– Calculation of complex kinematic

transformations







Increase of energy efficiency: Power monitoring

– Acquisition of energy consumption data

– Data transmission to superior systems

Increase of availability: Condition monitoring

– Vibration monitoring

– Data analysis on the control

– Data transmission to superior systems







Process reliability: Monitoring

– Measurement of differential pressure

– Monitoring of vacuum for part handling

Manipulation and visualization: HMI

– Multi-touch Panel with TC HMI

– Integration of third party hardware





Beckhoff Industrie 4.0 Demonstration

Cloud ServicesVerl

Headquarters

Verl, Germany

Pub/Sub

Hall 9, F06 Hall 9, F06 Hall 7, C40

Outdoor, R139

Pub/Sub

Hall 16, A04

Pub/Sub

Pub/SubPub/SubPub/Sub



Project overview




Summary

28


Partner

Increased reliability, sustainability and quality of the production systems

8 % increase in productivity

10 % reduction in energy consumption

8 % reduction in lead times

50 % reduction in scrap rate

20 % reduction in emissions and immissions

30-40 % increase in tool service life

Regional benefits

Stabilization of lectures at universities, of further education, of research

lead to qualified people

Transfer of special knowledge about different technologies

will increase the competitiveness of local companies


Benefits for participants in the project

Documents

Research Project | itsOWL-ScAut - BECKHOFF New … · · 2017-07-19intelligent feedback control system with PC-based control ... Programming in IEC 61131-3 and the C or C++ languages